CN101478191B - Process for producing wind power generator by casting technique - Google Patents
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- CN101478191B CN101478191B CN2009100583023A CN200910058302A CN101478191B CN 101478191 B CN101478191 B CN 101478191B CN 2009100583023 A CN2009100583023 A CN 2009100583023A CN 200910058302 A CN200910058302 A CN 200910058302A CN 101478191 B CN101478191 B CN 101478191B
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Abstract
The invention provides a method for producing the main shafts of a wind-driven generator by using the casting technology. The method comprises the following steps: firstly, the low and medium alloy steel contained with 0.1-0.6 percent of content of carbon is smelted, then the 0.001 to 0.2 percent of inoculant is scattered in and fully stirred, then is poured to a metallic mold, meanwhile, the magnetic field with strength of 1.5-10T is applied, and when the alloy liquid is crystallized, the variable-speed rotation is continuously carried out within the rotational speed of 50-300rpm under the driving action of a vertical centrifugal casting machine, the alloy liquid is filled and solidifies under the combined action of the feeding of the liquid metal of the dead head and the centrifugal force to form casting parts, the casting parts are taken out after being cooled to the temperature ranged from 650 to 750 DEG C, and finally, the annealing treatment is carried out. The provided casting process not only can replace the traditional forging process, ensures the shaping of the products easy, the texture of the casting parts dense and the mechanical property excellent, but also has high production efficiency, has low manufacture cost (the production cost can be reduced by above 40 percent), meanwhile, can reduce the rigorous threshold requirement of production of the main shaft of the wind-driven generator and enables the casting enterprises to produce the main shafts of the wind-driven generator.
Description
Technical field
The invention belongs to the production method technical field of wind driven generator principal shaft, be specifically related to the method that a kind of technology of utilizing gravitational casting and centrifugal casting to combine is produced wind driven generator principal shaft.
Background technology
At present, along with problems such as global energy shortage and environmental pollution are increasingly serious, the energy of searching and selection environmental protection and recyclability has become the key subjects that countries in the world face.And nature exists wind energy to compare with other energy, not only reserves are big, widely distributed, never exhausted, be water can 10 times, but also have last detective, construction period weak point, stronger, and can effectively contain greenhouse effect and sandstorm disaster, characteristics such as environmental protection than basic less investment, the flexibility of the construction of hydropower stations.Therefore, utilize wind power generation to become the important component part of global future source of energy development strategy and be subjected to the great attention of various countries and support energetically as new energy development.But, because it is not mature enough to make the technology of wind power equipment at present, causing the wind power plant costliness, cost of wind power generation is higher, and the wind-powered electricity generation electricity price is higher than coal electricity electricity price, thereby has restricted the fast development of wind-powered electricity generation.
One of key equipment of wind turbine generator is the main shaft of generator.At present, the method for making wind driven generator principal shaft both at home and abroad is to adopt forging method all.Its manufacturing process is: forge into blank after special steel is smelted, and then heat-treat and machining.But when utilizing forging method to produce, at first requirement the high-quality electric furnace refining must be provided steel ingot to satisfy the high-performance needs of product, secondly need to adopt special molding mode (forging) come crystal grain thinning so that the more good blank of obtained performance.The technical process that adopts forging method to produce blower fan main shafts as units such as Inner Monggolia North Heavy Industry Group Co.,Ltd and Deyang, Sichuan nine benefit forging Co., Ltds is roughly: alloy melting → steel ingot → forging → annealing → rough turn → modified → half finish turning → finish turning.Therefore, adopt not only complex manufacturing of forging method, formed product difficulty and ratio of briquetting are not high, following process difficulty, and high material consumption cause the production cost height, production efficiency is lower, the mechanical industry that some special steel enterprises and forging machine are little is difficult to produce, and causes the blower fan main shaft of production can not meet the need of market far away, and domestic quite a few blower fan main shaft needs import and costs an arm and a leg.
In the technical field of making method for casting, except forging method, also have centre spinning and gravitation casting method commonly used.Centrifugal casting (" centrifugal casting ", Zhang Baiming, China Machine Press, in June, 2004) method pours into alloy liquid in the casting mold exactly, then casting mold is fixed on the centrifugal casting machine rotation and reaches rated speed gradually, so that alloy liquid is at the action of centrifugal force lower charging type.Utilize tube drawing pincers or ejector sleeve machine that cast tube is taken out from casting mold after type solidifies when alloy liquid fills, the part foundry goods carries out subsequent treatment again.Centrifugal casting is divided into horizontal centrifugal casting and two kinds of vertical centrifugal castings according to the orientation of rotating shaft, horizontal centrifugal casting is mainly used in the production of draw ratio at the thin-wall pipe more than a times, and draw ratio is less than the normal method production of adopting vertical centrifugal casting of the bigger pipe fitting of one thickness.But traditional centre spinning method is mainly used in pipe box class foundry goods such as producing thin-wall pipe, cylinder jacket, roll, has not both seen that relevant report did not have manufacturer production yet and produce blower fan main shaft with centre spinning.Trace it to its cause mainly is that blower fan main shaft is a thick and large casting, draw ratio is far longer than one, does not all meet in the elongated thin-wall pipe more than a times and the method production draw ratio that the adopts vertical centrifugal casting principle less than one short and small thick and large casting with the method production draw ratio of the traditional horizontal centrifugal casting of employing.Because if adopt traditional horizontal centrifugal casting, can't pour into a mould because the centre bore of blower fan main shaft is little; If adopt traditional vertical centrifugal casting, because the blower fan main shaft foundry goods is long, centre bore is little, thickness is big, and because problems such as difficult forming and component segregation appear in the influence of centrifugal force easily.
Gravitational casting is meant that molten metal injects the technology of casting mold under the terrestrial gravitation effect, also claims casting.Gravitational casting generally includes sand casting, permanent mold casting, model casting, lost foam casting, mud die cast etc.Though traditional gravitation casting method can be made thick and large casting, but when producing thick and large casting, because the influence of factors such as slow, the uneven crystallization of cooling rate of liquid metal and feeding be insufficient in the casting mold and occur easily that crystal grain is thick, problems such as component segregation (being that composition is inhomogeneous) and shrinkage cavity shrinkage porosity, make the intensity of foundry goods and toughness lower.Obviously, if adopt traditional gravitation casting method to produce thick big blower fan main shaft, will inevitably lowlyer because of tensile strength, elongation and the impact toughness of blower fan main shaft cause it can not satisfy instructions for use.
Summary of the invention
The objective of the invention is problem at present prior art existence, a kind of method of utilizing foundry engieering to produce wind driven generator principal shaft is provided, provides a kind of casting method of utilizing gravitational casting and centrifugal casting to combine specifically and produce wind driven generator principal shaft.
The method of utilizing foundry engieering to produce wind driven generator principal shaft provided by the invention is phosphorus content low for 0.1-0.6% by weight percentage earlier, medium alloy steel carries out melting in smelting furnace, in casting forward direction liquid metal alloy liquid, be sprinkled into then by low, the weight of medium alloy steel is counted 0.001～0.2% inovulant and is fully stirred, be poured in the metal mold again, simultaneously metal mold is applied the magnetic field that intensity is 1.5-10T, treat alloy liquid be cooled to beginning during crystallization under vertical centrifugal casting machine drives, in rotating speed 50-300rpm, ceaselessly carry out the speed change rotation, and make alloy liquid at the feeding of dead head liquid metal and the acting in conjunction lower charging type of centrifugal force, solidify the formation foundry goods, take out when foundry goods is cooled to 650～750 ℃, carry out annealing in process at last.
The metal mold that the used metal mold of the present invention is preferably made with the ML20 steel, its inner surface scribble and in advance through the diatomite aqueous solution fireproof coating of intensive drying; To the feeding of dead head liquid metal is to carry out afterwards by numerical simulation in advance.
The inovulant with crystal grain thinning that the present invention is sprinkled in casting forward direction liquid metal alloy liquid is any among B, V or the Ti.When the inovulant that is sprinkled into was B, addition was 0.001-0.003%; When the inovulant that is sprinkled into was V or Ti, addition was 0.1-0.2%.
For intensity, toughness, the quenching degree that improves material, reduce temper brittleness, the present invention is added with Cr or the Ni that counts 0-0.35% by weight low, medium alloy steel in low, the medium alloy steel alloy of melting.
For reducing oxygen, hydrogen, sulphur and other impurity in the steel, eliminate Widmannstatten structure and column crystal, the step refining crystal grain of going forward side by side improves impact toughness, and the present invention also can add in low, the medium alloy steel alloy of melting and counts the rare earth element of 0-0.2% by weight low, medium alloy steel.Among the preferred Nd of rare earth element, Pr or the Ce any.
Compared with the prior art the present invention has the following advantages:
1, because the alternative traditional Forging Technology of the casting technique of utilizing gravitational casting to combine provided by the invention with centrifugal casting, liquid metal is poured into casting mold be cooled to liquid metal when beginning crystallization, utilize vertical centrifugal casting machine to drive the casting mold rotation again, make alloy liquid at the action of centrifugal force compacted under and by casting mold is carried out the cooling rate that water-cooled has increased alloy liquid, thereby not only can make formed product easy, foundry goods dense structure, mechanical performance is good, and production efficiency height, low cost of manufacture (can reduce production costs more than 40%), greatly strengthened the competitiveness of product in market, also reduced simultaneously blower fan main shaft has been produced harsh threshold requirement, made foundry enterprise all can carry out blower fan main shaft production.
2, since the present invention when the casting technique of utilizing gravitational casting to combine production blower fan main shaft, added the inovulant of some, thereby can carry out the good pouring temperature that breeds and reduce foundry goods, crystal grain thinning effectively alloy liquid with centrifugal casting.
3, because the inventive method is after molten steel pours into casting mold, just casting mold has been applied and to have hindered molten metal rotate and hinder wherein that the out-phase particle that produces floats or the electromagnetic field that sinks comes alloy liquid is carried out strong agitation with casting mold in casting mold, and when alloy liquid begins crystallization, under the condition of not stopping the conversion rotating speed, carry out centrifugal casting again, both made and produced very big relative flowing (forming turbulent flow) between molten metal and the casting mold, the solidification layer that casting mold is rotated together produces bigger scouring force again, make the crystal grain of foundry goods change tiny equi-axed crystal into by general bigger tabular and columnar grain, thereby both efficiently solved the thick and lower problem of performance of crystal grain that thick and large casting occurs easily in traditional gravitational casting process, solved the component segregation problem that occurs easily in traditional centrifugal casting process again well.
4, since the inventive method to the feeding of dead head liquid metal by carrying out afterwards by numerical simulation in advance, simultaneously, by on the basis of gravitational casting, implementing centrifugal casting technique again, make molten steel in process of setting, before the microcosmic feeding passage sealing of foundry goods, not solidified molten steel is added in the microshrinkage of process of setting generation by action of centrifugal force, thereby further strengthened feeding to foundry goods, avoid in traditional gravitational casting process the generation of the insufficient and microshrinkage shrinkage porosite of the feeding that occurs easily fully, greatly improved the performance of foundry goods.
5, also the composition of material is designed owing to the inventive method, added and to have reduced impurity and the intensity, toughness, the quenching degree that improve material in the steel, reduce the element of temper brittleness, and be aided with corresponding Technology for Heating Processing, thereby further improved the comprehensive mechanical property of foundry goods.
6, utilize casting method of the present invention to produce blower fan main shaft, not only can reduce the waste of alloy liquid, the ratio of briquetting height of product, but also the waste heat of self carries out subsequent heat treatment to foundry goods can make full use of foundry goods and just solidified the time, thus save the energy and reduced cost.
7, this new method that provides for the manufacturing of wind driven generator principal shaft of the present invention is not only simple ripe, be easy to grasp, and can make this environmental protection of wind power generation, reproducibility is strong and have the technology of bright prospects to be widelyd popularize.
Embodiment
Provide embodiment below so that the present invention is carried out concrete description; be necessary to be pointed out that at this following examples only are used for the present invention is further specified; can not be interpreted as limiting the scope of the invention, content still belongs to protection scope of the present invention to some nonessential improvement and the adjustment that the present invention makes to the person skilled in the art in this field according to the present invention.
In addition, percentage that what deserves to be explained is the used element of following examples all is weight percentage; The gained foundry goods has carried out tensile strength sigma
b, yield strength σ
s, elongation δ
5, reduction of area ψ, impact toughness A
Ku, the test of mechanical performances such as material hardness HB, wherein, the σ of material
b, σ
s, δ
5, ψ carries out on SHT4305 microcomputer controlled electro-hydraulic servo universal testing machine; A
KuOn JB-300S pendulum impact-toughness tester, carry out; HB carries out on HB-3000 type Brinell's machine.
Embodiment 1～12
The used material of the embodiment of the invention is four kinds of low, medium alloy steel, and its trade mark is respectively HY-130, ZG15MnMoVCu, ZG35SiMnMoV, ZG42CrMo, and its common separately chemical composition scope sees Table 1, and Fe is a surplus.
Table 1
In the fusion process of reality, with three kinds of composition alloys of the equal melting of the alloy of each trade mark as embodiment, concrete composition such as the table 2 of each embodiment, Fe is a surplus.
Table 2
Alloy by each embodiment in the table 2 carries out melting respectively in converter.In order to reduce P in the alloy as far as possible, S, O, impurity contents such as H are to improve toughness, adopt Mn iron in the melting later stage, Si iron and Al double deoxidizer etc. carry out sufficient deoxidation, the metering that provides by table 3 in low-alloy steel HY-130 and ZG15MnMoVCu before the liquid metal casting is sprinkled into B, the metering that provides by table 3 in medium alloy steel ZG35SiMnMoV is sprinkled into V, the metering that in steel alloy ZG42CrMo, provides by table 3 be sprinkled into Ti as inovulant with crystal grain thinning and fully stir, then it is poured into and makes with the ML20 steel, coat the fireproof coating of the diatomite aqueous solution on the inner surface in advance, drying also is preheated in the metal mold about 200 ℃, cover end cap, simultaneously metal mold is applied the magnetic field of respective strengths and casting mold is carried out water-cooled by table 3.When molten steel cools to beginning during crystallization under vertical centrifugal casting machine drives, ceaselessly carry out the speed change rotation in the rotating speed 50-300rpm to being molded in, and carry out the feeding of liquid metal with alloy liquid at dead head according to the numerical simulation of being done in advance, make it at centrifugal force the acting in conjunction lower charging type, solidify the formation foundry goods.When foundry goods is cooled to temperature shown in the table 3, take out, utilize the waste heat of foundry goods this moment itself that it is pushed in the annealing furnace then, under the condition of " 1000 ℃ * 4h+ air cooling+880 ℃ * 1h+ water-cooled+580 ℃ * 2h+ water-cooled ", heat-treat to improve its toughness.At last to its carry out machine work can obtain long for 2705mm, bottom maximum gauge be that 1380mm, top minimum diameter are that 510mm, weight are the blower fan main shaft of 6483kg.By test, the every mechanical performance index after foundry goods is modified sees Table 4.
Table 3
Table 4
Therefore four kinds of materials have all reached the performance index of blower fan main shaft instructions for use: σ through after the modifier treatment
b=685MPa, σ
s=540MPa, δ
5=14%, ψ=35%, A
Ku=39J, HB=228.Therefore, it is fully feasible blower fan main shaft being taked the mode of casting and forging.
Claims (4)
1. utilize foundry engieering to produce the method for wind driven generator principal shaft, this method is that low-alloy steel or the medium alloy steel that first phosphorus content by weight percentage is 0.1-0.6% carries out melting in smelting furnace, in casting forward direction liquid metal alloy liquid, be sprinkled into inovulant then and fully stir, be poured in the metal mold again, simultaneously metal mold is applied the magnetic field that intensity is 1.5-10T, treat alloy liquid be cooled to beginning during crystallization under vertical centrifugal casting machine drives, in rotating speed 50-300rpm, ceaselessly carry out the speed change rotation, and make alloy liquid at the feeding of dead head liquid metal and the acting in conjunction lower charging type of centrifugal force, solidify the formation foundry goods, when being cooled to 650～750 ℃, takes out on foundry goods, carry out annealing in process at last, wherein inovulant adopts B, V or Ti, and the weight B by low-alloy steel or medium alloy steel is 0.001-0.003%, and V or Ti are 0.1-0.2%.
2. the method for utilizing foundry engieering to produce wind driven generator principal shaft according to claim 1, this method is added with Cr or the Ni that counts 0-0.35% by the weight of low-alloy steel or medium alloy steel in the low-alloy steel of melting or medium alloy steel alloy.
3. the method for utilizing foundry engieering to produce wind driven generator principal shaft according to claim 1 and 2, this method is added with the rare earth element of counting 0-0.2% by the weight of low-alloy steel or medium alloy steel in the low-alloy steel of melting or medium alloy steel alloy.
4. the method for utilizing foundry engieering to produce wind driven generator principal shaft according to claim 3, the rare earth element that this method adds in the low-alloy steel of melting or medium alloy steel alloy are any among Nd, Pr or the Ce.
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| CN101618426B (en) * | 2009-07-25 | 2011-09-07 | 宁波明灵机械有限公司 | Method for casting main shaft casts of stators in aerogenerators |
| CN101921946B (en) * | 2010-08-12 | 2012-01-11 | 荆州环宇汽车零部件有限公司 | Method for producing high-grade nodular cast iron crank shaft by normalizing casting waste heat |
| CN110860659A (en) * | 2019-11-28 | 2020-03-06 | 中国船舶重工集团海装风电股份有限公司 | Wind generating set casting main shaft and casting process and casting mold thereof |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1603027A (en) * | 2004-06-04 | 2005-04-06 | 东北大学 | Low-frequency electromagnetic field horizontal continuous casting process and equipment for aluminum alloy and magnesium alloy |
| CN1904084A (en) * | 2006-08-09 | 2007-01-31 | 马鞍山市万鑫铸造有限公司 | Production method of high strength synthetic cast iron electric machine main shaft disk |
| CN200988095Y (en) * | 2006-10-19 | 2007-12-12 | 上海大学 | Metal electromagnetic continuous casting device |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1603027A (en) * | 2004-06-04 | 2005-04-06 | 东北大学 | Low-frequency electromagnetic field horizontal continuous casting process and equipment for aluminum alloy and magnesium alloy |
| CN1904084A (en) * | 2006-08-09 | 2007-01-31 | 马鞍山市万鑫铸造有限公司 | Production method of high strength synthetic cast iron electric machine main shaft disk |
| CN200988095Y (en) * | 2006-10-19 | 2007-12-12 | 上海大学 | Metal electromagnetic continuous casting device |
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